Hydrostress SB User manual

BAEA-SB-000 / 962715 SB_0107_e.mif
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SB Wire Sawing System
Page 2 SB_0107_e.mif
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Dear Customer
You have decided to buy a HYDROSTRESS sys-
tem and have thus acquired a highly sophisticated
and reliable state-of-the-art unit.
Due to our special efforts in the field of quality
assurance, the SB wire sawing system is another
top-of-the-range Swiss product with the following
properties:
Unprecedented power-to-weight ratio
Reliable operation
High mobility
Easy handling
Low maintenance costs
The exclusive use of genuine HYDROSTRESS
spare parts ensures quality and interchangeability.
In the case of neglected or inappropriate mainte-
nance, we refuse to accept any warranty commit-
ment as specified in our terms of delivery.
Any repair work is to be carried out by trained spe-
cialist personnel only.
Should you need more details concerning your
HYDROSTRESS system in order to keep it in per-
fect condition, please contact our after-sales ser-
vice for further information.
We hope that you will not experience any difficulties
while working with your
HYDROSTRESS system.
HYDROSTRESS AG
Management
Copyright © HYDROSTRESS AG, 2001
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This operating manual is only valid for the
following system:
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This manual only describes the SB Wire
Sawing System (hereafter only referred to by
"SB") without connectable equipment (drives).
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Notes in this manual referring to the operation
of connectable equipment are designed to
increase the safety of the operating personnel.
In order to operate this equipment safely, the
relevant operating instructions have to be
followed as well.
HYDROSTRESS AG
Witzbergstrasse 18
CH-8330 Pfäffikon
Switzerland
Phone [phone]
Fax [phone]
SB Wire Sawing System, Index 000

SB Wire Sawing System
SB_0107_e.mif Page 3
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1.1 Fundamentals 4
1.2 Inherent dangers of wire saws 6
1.3 Intended purpose 7
1.4 Before starting work 8
1.5 After work 8
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2.1 Possible cutting capacity 9
2.2 Dimensions 9
2.3 Weight 9
2.4 Wire drive 10
2.5 Connectable drives 10
2.6 Wire running direction 10
2.7 Wire cutting speed 11
2.8 Wire lengths 12
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7.1 Setting up the SB 17
7.2 The correct cutting direction 18
7.3 Finish cutting 18
7.4 Flush cutting against a wall 19
7.5 Flush cutting against the floor 19
7.6 End of cut 19
7.7 Establish removal direction 19
7.8 Rounding off the structural body 20
7.9 The cutting sequence 20
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8.1 Example of CR-5 RC 21
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9.1 Types of diamond wire 24
9.2 Preparation of wire ends 25
9.3 Avoiding out-of-round wear 25
9.4 Connect wire 30
 ,QVHUWZLUH 
10.1 Insert wire, general. 32
10.2 Insert wire, 1st step 33
10.3 Insert wire, 2nd step 33
10.4 Insert wire, 3rd step 33
10.5 Insert wire, 4th step 33
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11.1 Store wire, 1st step 34
11.2 Store wire, 2nd step 34
11.3 Store wire, 3rd step 34
11.4 Store wire, 4th step 34
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12.1 Pull wire through by hand 36
12.2 Switch on drive unit 36
12.3 Presetting the feed 36
12.4 Letting the wire run 36
12.5 Operation 37
12.6 Interruption of cut 37
12.7 End of cut 37
12.8 Terminate operation 37
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14.1 Maintenance table 41
14.2 Repairs 41
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15.1 Transport 42
15.2 Putting out of operation, storage 42
15.3 Disposal 42
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16.1 Accessories delivered together
with the SB 43
16.2 Accessories which can be ordered 43
16.3 Spare parts lists, ordering details 43

Safety instructions SB Wire Sawing System
Page 4 SB_0107_e.mif
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Machining concrete is neither simple nor
without risk. Material assets on the site, the
machine itself and the safety of people are at
stake.
The operating personnel must therefore be
trained by experienced specialists.
HYDROSTRESS can support you in your
training.
Only specially trained and qualified personnel
may carry out maintenance and repair work
and any other work on the following com-
ponents:
l Electrical equipment
l Hydraulic equipment
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This operating manual contains important
information on how to operate the machine
safely and efficiently.
The owner of the machine must make sure
that the instructions in this manual are followed
by every person having anything to do with the
machine, or with the respective auxiliary and
operating resources.
The operating manual must be accessible on
the site at all times.
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The machine has been built in accordance
with state-of-the-art standards and the rec-
ognized safety regulations. Nevertheless, its
use may constitute a risk to the life and limb of
the user or of third parties, or cause damage to
the machine and to other property.
Pay attention to the special working conditions
on the building site. Protect yourself and
others within your responsibility against the
many hazards!

SB Wire Sawing System Safety instructions
SB_0107_e.mif Page 5
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Depending on the working environment, the
machine can cause excessive noise during
operation.
The noise can permanently damage the
hearing of operating personnel and of other
people nearby within a very short time.
Ear protectors must therefore always be worn
during machining.
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Pay attention to the following words, their
symbols and their meaning:
Danger:
Warning:
Important:
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Safety clothing must always be worn when
drilling, sawing, crushing or bursting concrete
or stone in order to protect against the
following hazards:
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Falling parts: Helmet, steel-capped (safety) shoes
Moving, sharp-edged parts: Safety gloves
Flying pieces of concrete and stone: Safety glasses
Flying sparks: Safety glasses
Slipping: Antislip shoes
Noise: Ear protectors
Contamination of respiratory tracts: Mask
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Only the following materials may be machined
with HYDROSTRESS equipment:
- Reinforced concrete
- Natural stone
- Masonry
Other materials are not to be machined.
Especially avoid machining:
- Wood
-Plastic
-Glass
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- The sawingof parting cuts
- Flush cutting
- Angular cuts
Special information to prevent
personal injury
Special information to prevent damage to
the machine
Special information on how to use the
machine most efficiently

Safety instructions SB Wire Sawing System
Page 6 SB_0107_e.mif
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Only use the machine together with the rec-
ommended connectable devices (see "Con-
nectable devices" in this manual)
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Observe the general and special accident pre-
vention regulations of the trade associations in
your country!
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Dangers caused by electrical drive units and
rotating pulleys are adequately described in
the respective wire sawing equipment
operating manuals. Other dangers must be
strictly avoided by protecting the operating
personnel and other persons not involved in
sawing work.
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Wire cracks can be prevented by selecting
large contact angles. In spite of this wire
cracks can never be 100% excluded.
Therefore all the protective equipment must
always be installed.
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A cracked wire can fling off a loose diamond
bead if it strikes against something.
The wire normally runs at between 15 and
25 m/s, which means that a loose diamond
bead could be flung off at up to 100 m/s.
Suitable protective equipment must be
installed to catch such diamond beads when
they are flung off.
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l Only use high quality diamond wire and
beads
l Make sure that the operating personnel
know how the wires are safely connected
l Make sure that the operating personnel
know that high wire tensions can cause wire
cracks
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l Only use the protective measures recom-
mended by the manufacturer
l Ensure that all zones are protected into
which a flung-off diamond bead can fly
l In any case install all possible guards
around the danger zone

SB Wire Sawing System Safety instructions
SB_0107_e.mif Page 7
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l Wood (min. 20mm)
l Sheet metal (aluminium, min. 3 mm,
steel, min. 2 mm)
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Safety never comes free. The setting up of
wire sawing operations must always include
the setting up of all the protective equipment
as described above. The time and material for
these installations must be taken into account
when preparing quotations for the customers.
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The intended purpose of the wire saw is the
sawing of the materials described above with
an 11 mm diameter diamond wire (sintered)
and 10 mm (electro-plated). Any other use can
lead to dangers and will exclude any possibility
of liability being accepted by
HYDROSTRESS / TYROLIT.
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These can be very heavy:
Example:
A one metre square cube weighs about 2.5
tonnes.
Make sure that such parts do not fall outside
the restricted zone.
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Only use the machine with the recommended
drives and their respective accessories.

Safety instructions SB Wire Sawing System
Page 8 SB_0107_e.mif
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Make sure that the machine can quickly stop in
the event of an emergency (see "Emergency
stop" in the operating instructions for the drive
being used)!
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Find out how you can obtain fast help in the
event of an accident!
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Make sure that any such lines, which are in the
vicinity of your cut, are out of operation! Find
out if the lines can safely be cut through.
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Find out if all types of reinforcement steel in
your cutting zone or your hole can be cut
through. If necessary the cut may have to be
relocated by agreement with the customer.
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Organize your workplace well! This will signif-
icantly reduce the risk of accidents!
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Make sure that your working area is well lit.
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The machine is designed for operation by one
single person.
During operation third parties must stand at a
safe distance from the machine.
The drive unit must be positioned such that all
the control elements can be easily reached.
In particular it must be possible to stop the
machine quickly and safely (see "Emergency
stop" in the operating instructions for the drive
being used).

SB Wire Sawing System Safety instructions
SB_0107_e.mif Page 9
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Machines with motorized feed are not
automatic machines. They have to be con-
stantly monitored during operation. An
emergency stop must be possible at any time.
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So that you cannot be caught up by rotating or
moving parts always wear tightly-fitting
clothing and a hair net if you have long hair!
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After work always pull out the mains plug of
the drive being used to prevent it from being
unintentionally switched on again!
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Use suitable lifting equipment for the removal
of these sections in order to avoid injuries.

Technical data SB Wire Sawing System
Page 10 SB_0107_e.mif
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The cutting capacity of the SB, when driven by
a high-performance drive unit (e.g. RD-S /
RD-S RC) can be up to 3.5 m2of concrete per
hour according to the amount of reinforcement
steel and the aggregate materials.
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SB Wire Sawing System Technical data
SB_0107_e.mif Page 11
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Hydraulic motors with size 3 connections.
Absorption volumes: 20, 25 and 31 ccm.
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All types of hydraulic drives with at least one
hydraulic feed can be connected.
We recommend high-performance drives with
a power of at least 20 kW to achieve the
expected cutting capacity of the SB.
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-CR-3
-CR-5RC
-DKUSA
-AD-S
-AD-S2
-AD-S3
-AD-S4
- AD-S4 RC
-RD
-RD-2
-RD-S
- RD-S RC
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The running direction of the wire is preset by
the direction of movement of the hydraulic
motor and the design of the drive pulley (free-
running) and cannot be changed.

Technical data SB Wire Sawing System
Page 12 SB_0107_e.mif
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The optimum cutting speed for standard appli-
cations is 20-25 m/s (values in bold type).
You can set the correct wire cutting speed with
the correct choice of litre flow rate (with multi-
stage drives) and the hydraulic motor. In this
way you can achieve:
- Optimum sawing performance
- The best service life for thewire
- Less wire cracks
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If there is a lot of steel reinforcement or if hard
aggregates are found the wire cutting speed
should be reduced.
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Switch back by one stage
This causes the wire cutting speed to be
reduced by 4-5 m/s.
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With single-stage drives, the hydraulic motor
can be changed (use larger motor).
This causes the wire cutting speed to be
reduced by 4-5 m/s.
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Motor Stage 1
33 l/min Stage 2 40 l/min Stage 3 50 l/min Stage 4 60 l/min
20 ccm
976164 16 m/s 19 m/s PV 28 m/s
25 ccm
976165 12 m/s 15 m/s 19 m/s PV
31 ccm
976166 10 m/s 12 m/s 15 m/s 18 m/s
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Motor Stage 1
45 l/min Stage 2 55 l/min Stage 3 63 l/min Stage 4 73 l/min
20 ccm
976164 PV PV 30 m/s 34 m/s
25 ccm
976165 17 m/s PV PV 28 m/s
31 ccm
976166 14 m/s 17 m/s 19 m/s 22 m/s
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Motor Stage 1
65 l/min Stage 2 75 l/min Stage 3 80 l/min Stage 4 90 l/min
20 ccm
976164 31 m/s 35 m/s 38 m/s 42 m/s
25 ccm
976165 PV PV 30 m/s 34 m/s
31 ccm
976166 PV PV PV PV

SB Wire Sawing System Technical data
SB_0107_e.mif Page 13
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The forward feed movement takes place with
the drawing in of the wire into the machine. For
this purpose the rocker with the driving pulleys
is swivelled upwards. The wire lengths, which
are thereby drawn into the machine are shown
in the "Wire lengths" table.
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(Rocker in top position) 7RWDOOHQJWK
L1 Without storage 5.50 m 2.00 m (L1 + L2) = 7.50 m
L1 + Storage A 7.50 m + 2.00 m = 4.00 m (L1 + L2) = 9.50 m
L1 + Storage B 9.50 m + 2.00 m = 6.00 m (L1 + L2) = 11.50 m
L1 + Storage C 11.50 m + 2.00 m = 8.00 m (= L1 + L2) = 13.50 m
L1 + Storage D 13.50 m + 2.00 m =P (= L1 + L2) = P

Safe and efficient operation SB Wire Sawing System
Page 14 SB_0107_e.mif
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To achieve a safe and efficient operation, we
recommend that you proceed as follows:
7DVN 5HIHUHQFH
Read safety instructions See “1.2, Inherent dangers of wire saws” on Page 6
Transport machine See “15.1, Transport” on Page 42
Set up the SB machine See “7, Applicational advice” on Page 18
Sequence of cuts See “7, Applicational advice” on Page 18
Establish wire lengths See “2.8, Wire lengths” on Page 13
Connect SB See “8, Connection of hydraulics and water” on
Page 22
Connect wire See “9.4, Connect wire” on Page 31
Insert wire See “10.1, Insert wire, general.” on Page 33
Store wire See “11.1, Store wire, 1st step” on Page 35
Determine wire cutting speed See “2.7, Wire cutting speed” on Page 12
Run up wire saw See “12, Run up wire saw” on Page 36
Interrupt cut See “12.6, Interruption of cut” on Page 38
Stop work See “12.8, Terminate operation” on Page 38
Maintenance See “14.1, Maintenance table” on Page 41
Putting out of operation and storage See “15.2, Putting out of operation, storage” on
Page 42

SB Wire Sawing System Construction
SB_0107_e.mif Page 15
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1. Protective hood
2. Drive motor
3. Deflection pulley
4. Swivelling pulley
5. Clamping shackle
6. Lower deflection pulleys
7. Drive pulleys
8. Chassis handle
9. Crane hook
10. Rocker
11. Pulley guide for wire storage
12. Wheel
13. Storage area for clamping shackles
14. Hinged working table

Control elements SB Wire Sawing System
Page 16 SB_0107_e.mif
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:DWHUWDS
Water tap (2) for regulating the flushing of the
drive pulleys
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5ROOHUJXLGHV
The roller guide (8a) has 4 latched positions
and guides the wire to the correct storage
pulley.
During cutting work the locking screws on
the swivelling pulleys must be tight.
During cutting work the locking screws for
the roller guides (8b) must be tight.
Before servicing or adjusting the
SB the plug on the connected
drive unit must be pulled out.

SB Wire Sawing System Water
SB_0107_e.mif Page 17
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The water coming from the drive unit is led to
the water entry nozzle (1) and from there to the
individual points, which have to be cooled and
flushed through.
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Connect water supply hose from drive to this
point
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This regulates the water quantity for flushing
the drive pulleys (B)
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Lead flexible water supply hose to the drive
pulleys so that they are optimally flushed
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The water lances must be placed into the cut
at the wire entry points so that the wire is
optimally cooled.
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- Pressure: Min. 1 tomax.6 bar
- Water temperature: Max. 25°C
- Ensure thatthe water supply is not interrupted during
operation
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l Disconnect the water supply hose to the
drive being used
l Disconnect both water lances (A) and blow
them out
l Open water tap (2)
l Blow out the water hoses in the drive unit
hose set
Never connect the water supply hose
directly onto the SB. Instead always lead it
first through the drive unit in order to cool
the electric motor.
Never close the water tap during operation.
To avoid frost damage, if there is a risk of
frost the whole water system must be emp-
tied and blown out after work or before
longer operating breaks.
See also the operating instructions for the
drive unit being used.

Applicational advice SB Wire Sawing System
Page 18 SB_0107_e.mif
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Usually the SB is set up at a certain distance
from the structure (indirect erection), and the
wire is guided into the cut with the universal
trestle.
A: Horizontal cut
B: Vertical cut, flush
The SB is usually set up in a standing (vertical)
position. However if the space is limited it can
also be placed horizontally.

SB Wire Sawing System Applicational advice
SB_0107_e.mif Page 19
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The work should be carried out with the
tension side (Z) of the wire since the cutting
conditions are best with this method.
The wire can be guided by means of a
deflection pulley (U) so that in the case of
sharp edges the wire does not dig in.
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For finish cutting of the workpiece swing in
both swivelling pulleys so that:
1. The wire does not saw the inside ofthe holding
device and
2. Atthe end the wire is caught by the swivelling pulleys
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The swivelling pulley locking screws must
be tight during cutting work.

Applicational advice SB Wire Sawing System
Page 20 SB_0107_e.mif
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When flush cutting against walls the following
points must be borne in mind:
1. Set upSB at asuitable distancefromthe structure
2. Withtheuniversal trestle insert wire into the cut
3. Clamp a strip of timber (K) along the complete length
in order to guide the wireflush against the wall
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When cutting flush along the floor the following
points should be observed:
1. Set upmachine about 1 metre from the object
2. Guide wire and hold it right down with a wooden
beam (K).
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During cutting the swivelling rolls must be
swivelled inwards in steps more and more as
the cutting proceeds until at the end of the cut
they are in parallel.
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The removal of the sawn-out part must be
possible without danger. Make sure that these
parts cannot fall outside the restricted zone.
In certain cases it may be necessary to saw a
tapered shape so that the sawn-out part can
easily be removed from the opening.
Warning: To catch the wire when
it comes out of the cut a piece of
wood (H) must be fixed at the
exit point.
In order to swivel the swivelling
pulleys inwards it is essential
that the machine is stopped!